Patent Grant
8851362
The subject matter disclosed herein relates to containers, particularly to packing containers, and more particularly to packing containers suitably configured for stacking one on top of another.
Packing containers are often formed from a corrugated sheet product material that is cut with a die to form a flat blank, or scored and slotted to form a flat blank. The flat blank is folded into a three dimensional container that may be secured using an arrangement of flaps, adhesive liquids, or adhesive tapes.
In use, packing containers may be subjected to considerable forces during shipping, storage and stacking. It is desirable to increase the strength and rigidity of packing containers, particularly with respect to stacking, while reducing the amount of materials used to form the packing containers.
According to an embodiment of the invention, a container includes a plurality of panels integrally arranged with respect to each other and with respect to a set of orthogonal x, y and z axes, the z-axis defining a direction line in which the container is configured to support a stacking load. The plurality of panels include a first panel having a first planar surface, and a second panel having a second planar surface, wherein the first panel and the second panel form a contiguity with a fold line disposed therebetween, and wherein the first planar surface is disposed parallel to the x-z plane or the y-z plane. The container further includes a compression reinforcement feature having a planar edge oriented orthogonal to the first planar surface and perpendicular to the z-axis, the planar edge being disposed a distance away from the fold line but at a distance no greater than half a thickness of the first panel, the first panel having a void between the fold line and the planar edge.
According to an embodiment of the invention, a container includes a plurality of panels having a first side panel, a second side panel, a first end panel, and second end panel, a top panel and a bottom panel, the plurality of panels being integrally arranged with respect to each other to form a box having four lateral sides configured to support a stacking load when exerted in a z-direction from the top panel toward the bottom panel. The first side panel and a first portion of the top panel form a contiguity with a first fold line disposed therebetween. The second side panel and a second portion of the top panel form a contiguity with a second fold line disposed therebetween. A first compression reinforcement feature is disposed proximate the first fold line and proximate the first end panel. A second compression reinforcement feature is disposed proximate the first fold line and proximate the second end panel. A third compression reinforcement feature is disposed proximate the second fold line and proximate the first end panel. A fourth compression reinforcement feature is disposed proximate the second fold line and proximate the second end panel. Each of the first and second compression reinforcement features have a planar edge oriented orthogonal to the first side panel and perpendicular to the z-direction, each respective planar edge being disposed a distance away from the first fold line but at a distance no greater than half a thickness of the first panel, the first panel having a void between the first fold line and each respective planar edge. Each of the third and fourth compression reinforcement features have a planar edge oriented orthogonal to the second side panel and perpendicular to the z-direction, each respective planar edge being disposed a distance away from the second fold line but at a distance no greater than half a thickness of the second panel, the second panel having a void between the second fold line and each respective planar edge.
According to an embodiment of the invention, a container includes a plurality of panels integrally arranged with respect to each other and with respect to a set of orthogonal x, y and z axes, the z-axis defining a direction line in which the container is configured to support a stacking load. The plurality of panels include a first panel having a first planar surface, and a second panel having a second planar surface, wherein the first panel and the second panel form a contiguity with a fold line disposed therebetween, wherein the first planar surface is disposed parallel to the x-z plane or the y-z plane, and wherein the second panel is disposed orthogonal to the first panel. The container also includes a compression reinforcement feature having a planar edge oriented orthogonal to the first planar surface and perpendicular to the z-axis, the compression reinforcement feature includes a tab that extends from and is coplanar with the first panel and that terminates at the planar edge, the planar edge being disposed a distance away from a planar outer surface of the second panel but at a distance no greater than half a thickness of the first panel. The plurality of panels further comprises a third panel adhered to the outer surface of the second panel proximate the tab.
According to an embodiment of the invention, a container includes a plurality of panels having a first side panel, a second side panel, a first end panel, and second end panel, a top panel and a bottom panel, the plurality of panels being integrally arranged with respect to each other to form a box having four lateral sides configured to support a stacking load when exerted in a z-direction from the top panel toward the bottom panel. The first side panel and a first portion of the top panel form a contiguity with a first fold line disposed therebetween. The first side panel and a first portion of the bottom panel form a contiguity with a second fold line disposed therebetween. A first compression reinforcement feature is disposed proximate the first fold line and proximate the first end panel. A second compression reinforcement feature is disposed proximate the first fold line and proximate the second end panel. A third compression reinforcement feature is disposed proximate the second fold line and proximate the first end panel. A fourth compression reinforcement feature is disposed proximate the second fold line and proximate the second end panel. Each of the first and second compression reinforcement features have a planar edge oriented orthogonal to the first side panel and perpendicular to the z-direction, each of the first and second compression reinforcement features include a tab that extends from and is coplanar with the first side panel and that terminates at a respective planar edge, each respective planar edge being disposed a distance away from an outer surface of the top panel but at a distance no greater than half a thickness of the first panel. Each of the third and fourth compression reinforcement features have a planar edge oriented orthogonal to the first side panel and perpendicular to the z-direction, each respective planar edge of the third and fourth compression reinforcement features being disposed a distance away from the second fold line but at a distance no greater than half a thickness of the first side panel, the first side panel includes a void between the second fold line and each respective planar edge of the third and fourth compression reinforcement features.
According to an embodiment of the invention, a flat blank includes a first panel and a second panel that form a contiguity with a fold line disposed therebetween. The flat blank also includes a compression reinforcement feature formed by a cut line that begins at a first point on the second panel, traverses a first distance along a first line that extends across the fold line, traverses a second distance along a second line that runs substantially parallel to the fold line, and traverses a third distance along a third line that extends back across the fold line to end at a second point on the second panel, wherein the second line defines a location of a planar edge of the compression reinforcement feature, and wherein the planar edge is disposed a distance away from the fold line but at a distance no greater than half a thickness of the first panel.
According to an embodiment of the invention, a flat blank includes a first panel and a second panel that form a contiguity with a fold line disposed therebetween. The flat blank also includes a compression reinforcement feature formed by a cut line that begins at a first point on the first panel, traverses a first distance along a first line that extends across the fold line, traverses a second distance along a second line that runs substantially parallel to the fold line, and traverses a third distance along a third line that extends back across the fold line to end at a second point on the first panel, wherein the second line defines a location of a planar edge of the compression reinforcement feature, and wherein the planar edge is disposed a distance away from the fold line but at a distance no greater than a full thickness of the first panel.
According to an embodiment of the invention, a container includes a first panel comprising a planar surface, a second panel comprising a planar surface, wherein the first panel and the second panel form a contiguity with a fold line disposed therebetween, and a tabular region extending from the first panel, the tabular region arranged proximate to the fold line and coplanar with the planar surface of the first panel.
According to an embodiment of the invention, a container includes a bottom panel, a top panel opposing the bottom panel, a first side panel, a second side panel opposing the first side panel, a front panel, a rear panel opposing the front panel, and a first tabular region extending from the first side panel arranged coplanar with a planar surface of the first side panel.
According to an embodiment of the invention, a flat blank includes a first panel comprising a planar surface, a second panel comprising a planar surface, wherein the first panel and the second panel form a contiguity with a fold line disposed therebetween, and a tabular region defined by a cut line in the first panel.
According to an embodiment of the invention, a container includes a first panel comprising a planar surface, a second panel comprising a planar surface, wherein the first panel and the second panel form a contiguity with a fold line disposed therebetween, and a cut-out region of the second panel, the cut-out region partially defined by the fold line, a exposed edge of the first panel, the exposed edge partially defined by the cut-out region.
These and other advantages and features will become more apparent from the following description taken in conjunction with the drawings.
The subject matter, which is regarded as the invention, is particularly pointed out and distinctly claimed in the claims at the conclusion of the specification. The foregoing and other features, and advantages of the invention are apparent from the following detailed description taken in conjunction with the accompanying drawings in which:
A packing container, also referred to as a carton or simply as a container, may be fabricated by, for example, cutting or scoring a sheet product with a die or other type of cutting or scoring tool, such as cutting, scoring and slotting tooling and equipment, to form a flat sheet having various panels, flaps, tabs, recesses and creases. The sheet may be folded and secured using, for example, adhesive liquids, tapes or mechanical means such as staples or straps to form a three dimensional packing container. Packing containers may be formed from a variety of sheet products. The term “sheet products” as used herein is inclusive of natural and/or synthetic cloth or paper sheets. Sheet products may include both woven and non-woven articles. There are a wide variety of nonwoven processes and they can be either wetlaid or drylaid. Some examples include hydroentangled (sometimes called spunlace), DRC (double re-creped), airlaid, spunbond, carded, and meltblown sheet products. Further, sheet products may contain fibrous cellulosic materials that may be derived from natural sources, such as wood pulp fibers, as well as other fibrous material characterized by having hydroxyl groups attached to the polymer backbone. These include glass fibers and synthetic fibers modified with hydroxyl groups. Sheet product for packing containers may also include corrugated fiber board, which may be made from a variety of different flute configurations, such as A-flute, B-flute, C-flute, E-flute, F-flute, or microflute, for example.
In use, a packing container may be subjected to various forces during handling, shipping and stacking of the packing container including, for example, compressive forces exerted between the top and bottom panels of the container. It is desirable for a packing container to withstand the various forces to protect objects in the container and to maintain a presentable appearance following shipping. It is also desirable to reduce the amount of materials used to form the packing container while maintaining design specifications for strength and rigidity.
In an embodiment of a container having one or more symmetrical panels oriented parallel with the x-y plane (discussed below) it has been found, with respect to the symmetrical panel, that a compression reinforcement feature formed by removal or displacement of a small amount of container sidewall material below an upper fold line (or above a lower fold line) on a length-wise side panel of the container can improve stacking strength (also herein referred to as compression strength) of the associated container, while in an embodiment of a container having one or more asymmetrical panels oriented parallel with the x-y plane (also discussed below) it has been found, with respect to the asymmetrical panel, that a compression reinforcement feature formed by extending a small amount of container sidewall material, such as in the form of a tab, above an upper fold line (or below a lower fold line) on a length-wise side panel on an edge proximate a folded over lap joint, can improve stacking strength of the associated container. Such findings are based on substantial experimentation, both design of experiments experimentation and empirical experimentation, involving many parameters, where some of the parameters were found to be statistically significant, while other ones of the parameters were found to be statistically insignificant.
As used herein, reference to side panels and end panels, also referred to in combination as lateral panels, is in reference to those panels oriented orthogonal to the x-y plane (see
As used herein, the terms orthogonal (perpendicular) and parallel should be interpreted as being substantially orthogonal (perpendicular) and substantially parallel, respectively. For example, the term orthogonal in relation to planar surfaces should be interpreted to include two planar surfaces having an angle therebetween from 85-degrees to 95-degrees, or more typically from 88-degrees to 92-degrees, depending on whether the measurement is taken when the container is in a non-compressed state or a compressed state. And the term parallel in relation to planar surfaces should be interpreted to include two planar surfaces having an angle therebetween from +5-degrees to −5-degrees, or more typically from +2-degrees to −2-degrees, depending on whether the measurement is taken when the container is in a non-compressed state or a compressed state.
As used herein, any reference to a dimension or a percentage value should not be construed to be the exact dimension or percentage value stated, but instead should be understood to mean a dimension or percentage value that is “about” the stated dimension or percentage value, except where it is clear from the description and usage as presented herein.
The number of CRFs 1114, the arrangement of the CRFs 1114, and the dimensions of the CRFs 1114 have been found to improve the compression strength of the container 100 depending on the dimensions of a particular container and the materials used to fabricate the container. Thus, the illustrated embodiments of
With respect to symmetrical and asymmetrical panels, and with reference to
While
As mentioned above,
Folding the sheet product to form the edges 103 and 105 compresses the corrugated sheet between the opposing liner boards which may, for example, result in buckling, sagging, or shearing when an excessive compressive force is applied in a direction along the lines 150, that is, along a direction line parallel to the z-axis. The CRFs 1114 remain coplanar with the respective side panels 102 and 104, and are not folded or creased when the container 100 is assembled. More particularly, the cut line 1020 forming each CRF 1114 is not deformed when the container 100 is folded. Thus, the corrugated sheet material in the CRFs 1114 remains unfolded and may withstand greater compressive forces than the adjacent folded edges 103 and 105. As such, it will be appreciated that the recesses 1050 form the compression reinforcement features (CRFs) 1114 on the container 100. Similarly, folding the sheet product to form edge 123 also compresses the corrugated sheet. However, CRFs 214 remain coplanar with the side panel 104. Thus, the corrugated sheet material in the CRFs 214 remains unfolded and may likewise withstand greater compressive forces than the adjacent folded edge 123. As such, it will be appreciated that the tabs 214 form the compression reinforcement features (CRFs) 214 on the container 100.
Experimental testing of the container 100, where side panels 102 and 104 are different dimensions, using a box compression test (BCT) has shown an improvement in BCT results up to 11% over similar containers that did not include the tabs 214.
The testing results varied depending on the arrangement and number of tabs. In this regard, a control container having no tabs was found to have a BCT of 384±9 lbs. A first test container having two tabs similar to the tabs 214 depicted in
With reference to
With reference to
Comparing
While embodiments have been described herein having particular characteristic dimensions such as “d”, “e”, and “½e”, for example, it will be appreciated that respective tabs of CRFs 214 need not all be the same height relative to the fold line 123, and that respective recesses 1050 of CRFs 1114 need not be all the same height relative to the fold line 103.
Referring now to
With reference now to
As a side note, when referring to the height of the tabs of CRFs 214 discussed above, reference may be made herein to a positive dimension, such as + 3/32 of an inch, to indicate the presence of side panel material forming the tab, and when referring to the distance d of recess 1050, reference may be made herein to a negative dimension, such as − 3/32 of an inch, to indicate the absence of side panel material forming the recess.
With reference to
In another embodiment, and with reference to
In another embodiment, and with reference to
While
Referring to
With reference to
In the embodiment of
As discussed above, CRFs 214, 1114 may be located on upper and/or lower edges (relative to the z-axis depicted in
In an embodiment, and with reference to
In an embodiment, compression reinforcement features 1114a, b, c, d, e, f, g, and h, are arranged in pairs along respective edges of container 1100 as illustrated in
While reference is made herein to a container 100, 1100 having certain overall dimensions, it will be appreciated that such noted dimensions are merely to establish an order of magnitude and not to be construed as being exact. For example, a container formed in accordance with an embodiment of the invention may fall anywhere within the dimensional window having a minimum envelope size defined by a 5-inch cube, and a maximum envelope size defined by a 50-inch cube, where the container may or may not be a cube.
In view of the foregoing, it will be appreciated that an embodiment of the invention includes a container 100, 1100 having a plurality of panels that includes a first side panel, a second side panel, a first end panel, and second end panel, a top panel and a bottom panel, the plurality of panels being integrally arranged with respect to each other to form a box having four lateral sides and configured to support a stacking load when exerted in a z-direction from the top panel toward the bottom panel. Wherein the first side panel and a first portion of the top panel form a contiguity with a first fold line disposed therebetween. Wherein the second side panel and a second portion of the top panel form a contiguity with a second fold line disposed therebetween. Wherein a first compression reinforcement feature is disposed proximate the first fold line and proximate the first end panel. Wherein a second compression reinforcement feature disposed proximate the first fold line and proximate the second end panel. Wherein a third compression reinforcement feature disposed proximate the second fold line and proximate the first end panel. Wherein a fourth compression reinforcement feature disposed proximate the second fold line and proximate the second end panel. Wherein each of the first and second compression reinforcement features have a planar edge oriented orthogonal to the first side panel and perpendicular to the z-direction, each respective planar edge being disposed a distance away from the first fold line but at a distance no greater than half a thickness of the first panel, the first panel having a void between the first fold line and each respective planar edge. Wherein each of the third and fourth compression reinforcement features have a planar edge oriented orthogonal to the second side panel and perpendicular to the z-direction, each respective planar edge being disposed a distance away from the second fold line but at a distance no greater than half a thickness of the second panel, the second panel having a void between the second fold line and each respective planar edge.
Through substantial experimentation, discussed further below, it has be found that CRF's 214 (tabs) are advantageous on such a container as depicted in
It will be appreciated that a compression strength of a container could be dependent upon many variables associated with the container, such as a length, a width, a height of the container, the material forming the container, the type of fluting of fluted material forming the container, and the thickness of material forming the container, for example. Also, and in the case of the container having one or more of the aforementioned compression reinforcement features, the compression strength of the container could be dependent upon a length of the compression reinforcement feature, placement of the compression reinforcement feature, a height dimension (plus or minus) of the compression reinforcement feature, and a quantity of the compression reinforcement features. Through the use of exhaustive design of experiment (DOE) modeling, the following has been found.
With reference now to
With reference now to
With reference now to
Referring to Table-1 as an example, a container 1100 having a CRF 1114 as discussed above disposed on a length-wise edge 1103 of the container 1100 (see Column-1 parameter labeled “Tab Height-Length Panel [−½ caliper]”), has a DOE BCT result that is +29.397971 pounds stronger than the normalized intercept value. However, it is not only the scaled estimates that are of interest, but also the probability of statistical significance that is presented in Column-4, which in this example has a value of 0.0015. For DOE's it is accepted practice that if a level of significance for an estimated parameter is equal to or greater than 95% probability, then the results of that parameter is considered to be statistically significant. With respect to Column-4, equal to or greater than 95% probability equates to a “Prob>|t|” value of equal to or less than 0.05. As such, the subject CRF 1114 with a ½ caliper recess has a probability of being statistically significant in improving the compression strength of the container 1100.
By referring to Tables-1, 2 and 3 in combination, several parameters show up as being statistically significant in improving the compression strength of a container. However, for a given container size one of the aforementioned parameters consistently shows up as being statistically significant, which is the parameter in each Column-1 labeled “Tab Height-Length Panel [−½ caliper]”. This parameter correlates with the CRF 1114 discussed above in connection with
It is noteworthy, however, to also consider parameters that appear to have statistical significance in one or more, but not all, of Tables-1, 2 and 3. For example, the parameter labeled “Corner Space [At corner]” has equal to or greater than 95% probability of being advantageously statistically significant in Tables-1 and 3, and the parameter labeled “Tab Length [20%]” has equal to or greater than 95% probability of being advantageously statistically significant in Table-3.
The parameter labeled “Corner Space [At corner]” refers to a CRF 214, 1114 that is located closer to a corner of the container than to a center region of the container, and the parameter labeled “Tab Length [20%]” refers to a CRF 214, 1114 having a length that is 20% of the length of the edge of the container on which it is located, both of which will now be discussed further with reference back to
With reference to
A first set of test results showed that the RSC 1100 had improved compression strength when the centers of the CRFs were placed a distance of 3.5 inches from the end of the container, versus being placed substantially at the end of the container, and versus being placed 5.5 inches from the end of the container. However, all three placements showed an improvement in compression strength over a baseline RSC 1100 having no CRFs at all, the most advantageous placement (centerline at 3.5 inches from container end) had an improvement of 11%.
A second set of test results showed that the RSC 1100 had improved compression strength when the length of the CRFs were 20-30% of the edge length of the RSC (on a lengthwise side of the RSC), versus being 10% or 40%. However, all four lengths showed an improvement in compression strength over a baseline RSC 1100 having no CRFs at all. While the most advantageous length was 30%, having an improvement over the baseline RSC of 12.5%, an 11.2% improvement was found for a 20% length, a 4.4% improvement for a 10% length, and a 3.6% improvement for a 40% length.
From all of the foregoing substantive DOE's and empirical tests, it was found that two types of CRFs 214 (tabs) and 1114 (recesses) can be advantageous in improving the compressive strength of a respective container 100 and 1100, when strategically used and placed as disclosed herein.
For a container 100, such as an overlapped container as depicted in
For either the container 100 or the container 1100, respective CRFs 214, 1114 having a length of 10-30% of the length of the container have been found to be advantageous, and respective CRFs 214, 1114 having a respective centerline located at a distance from the end of the container that is between 25-40% of the length of the container have been found to be advantageous.
For the container 100, placing CRFs 214 only on one edge, the edge proximate the glued overlap as depicted in
While the invention has been described in detail in connection with only a limited number of embodiments, it should be readily understood that the invention is not limited to such disclosed embodiments. Rather, the invention can be modified to incorporate any number of variations, alterations, substitutions or equivalent arrangements not heretofore described, but which are commensurate with the spirit and scope of the invention. Additionally, while various embodiments of the invention have been described, it is to be understood that aspects of the invention may include only some of the described embodiments. Accordingly, the invention is not to be seen as limited by the foregoing description, but is only limited by the scope of the appended claims.
This application claims the benefit of U.S. Provisional Application Ser. No. 61/379,808, filed Sep. 3, 2010, which is incorporated herein by reference in its entirety.
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